Wood burning fireplace assembly with automatic igniter

ABSTRACT

A fireplace assembly having a firebox, an igniter assembly coupled to the firebox and containing a heating element, a first portion of the igniter assembly extending through an aperture in a firebox wall, the igniter assembly having a first connector coupled to the heating element and coupleable to power source, and having a second connector coupleable to an air source and positioned to provide air flow through the igniter assembly over the heating element and into the firebox. A controller is operatively coupled to the igniter assembly and a temperature sensor. The controller controls operation of the heating element, the temperature sensor, and the air flow through the igniter assembly, and can activate and deactivate the igniter assembly based upon the temperature within the firebox.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional PatentApplication No. 61/494,798 filed Jun. 8, 2011 entitled WOOD BURNINGFIREPLACE ASSEMBLY WITH AUTOMATIC IGNITER, and is incorporated herein byreference in its entirety.

TECHNICAL FIELD

Embodiments of the present invention are directed to fireplaceassemblies, and more particularly to wood burning fireplace assemblies,including fireplaces, inserts and stoves.

BACKGROUND

Conventional wood burning fireplaces are configured to allow a user toload wood and other suitable solid fuel into the firebox in a selectedarrangement before lighting the fuel to try to start the fire. Often auser must use a combination of paper, kindling, tinder, paraffin-basedfire starter, or the like, to “start the fire” in a manner to cause thelarger pieces wood to catch fire and to continue to burn. This manualprocess of lighting the fire can be time intensive, require multipleother materials, and can be frustrating if the fire won't “start”sufficiently to fully ignite the cut logs, rounds, or other largerpieces of wood. After the wood or other solid fuel has been ignited wheninitially manually starting the fire, the fuel often does not continueto burn and the fire will go out. Accordingly, the user must try torestart the fire and continue to tend the fire until the fuel issufficiently hot so as to continue to burn without going outprematurely. There is a need for a system to assist in starting andmaintaining a fire at a wood burning or other solid fuel burningfireplace assembly.

SUMMARY

The present invention is directed to a solid fuel burning fireplaceassembly with an automatic ignition system that overcomes drawbacksexperienced in the prior art and that provides additional benefits. Inaccordance with one embodiment, a fireplace assembly is provided forburning solid combustible fuel material. The fireplace assemblycomprises a firebox having walls that define an interior area, and anigniter assembly coupled to the firebox. The igniter assembly contains aheating element. The assembly has an ignition end that extends throughan aperture in one wall of the firebox. The ignition end is positionedin direct communication with the interior area, wherein the fuelmaterial can be immediately adjacent to the ignition end. The igniterassembly has a rear portion exterior of the fire box. The rear portionhas first and second connectors. The first connector is coupled to theheating element and is coupleable to power source. The second connectoris coupleable to an air source and is positioned to provide air flowover the heating element and out of the ignition end and into thefirebox for impingement with the combustible fuel.

A temperature sensor is connected to the igniter assembly and isconfigured to monitor the temperature within the firebox. A controlleris operatively coupled to the igniter assembly and the temperaturesensor. The controller controls operation of the heating element, thetemperature sensor, and the air flow through the igniter assembly. Thecontroller can activate and deactivate the igniter assembly based uponthe temperature within the firebox as sensed by the temperature sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a rear isometric view of a wood-burning fireplace assemblywith an automatic igniter system in accordance with aspects of thepresent invention.

FIG. 2 is a top plan view of the wood-burning fireplace assembly with anautomatic igniter system FIG. 1.

FIG. 3 is an enlarged cross-sectional plan view of the wood-burningfireplace assembly taken substantially along on line 3-3 of FIG. 1.

FIG. 4 is front elevation view of the wood-burning fireplace assemblywith an automatic igniter system of FIG. 1.

FIG. 5 is a front elevation view of a wood-burning fireplace assemblywith an automatic igniter system in accordance with another embodiment.

FIG. 6 is an enlarged cross-sectional plan view of the wood-burningfireplace assembly taken substantially along on line 6-6 of FIG. 5.

FIG. 7 is a side elevation of the wood-burning fireplace assembly ofFIG. 5.

FIG. 8 is an enlarged, partially cut away isometric view of the assemblyof FIG. 5 showing the igniter extending through a side wall.

Appendix A includes photographs of embodiments of the wood-burningfireplace assembly and features thereof.

DETAILED DESCRIPTION

The present disclosure describes solid fuel-burning fireplace assembly,such as a wood burning fireplace assembly, with an automatic ignitersystem in accordance with certain embodiments of the present invention.Several specific details of the invention are set forth in the followingdescription and the Figures to provide a thorough understanding ofcertain embodiments of the invention. Many of the details, dimensions,angles, relative sizes of components, and/or other features shown in theFigures are merely illustrative of particular embodiments of thedisclosure. Embodiments can have other details, dimensions, angles,sizes, and/or features without departing from the spirit and scope ofthe present disclosure. Moreover, certain features described withreference to specific embodiments may be combined with other embodimentsof the disclosure. Other details describing well-known structures andcomponents often associated with fireplace assemblies and methods offorming such assemblies, however, are not set forth below to avoidunnecessarily obscuring the description of various embodiments of thedisclosure. One skilled in the art, however, will understand that thepresent invention may have additional embodiments, and that otherembodiments of the invention may be practiced without several of thespecific features described below.

FIGS. 1-4 are views of a wood-burning fireplace assembly 10 with anautomatic igniter system 12 in accordance with one embodiment. Thewood-burning fireplace assembly 10 of the illustrated embodiment has afireplace housing 14 containing a firebox 16 (FIGS. 3 and 4). Thefirebox 16 is defined by a back wall 18, sidewalls 20, a top wall 22,and a bottom wall 23 all of which are sealably connected to each otherto define an interior area 26. The front of the firebox 16 is closableby a door 24. The interior area 26 is configured to receive wood orother solid combustible fuel material and to contain the fuel whenburning. The illustrated fireplace assembly 10 is a freestanding stove,although other embodiments can include fireplaces, inserts, or otherstoves.

The assembly 10 of the illustrated embodiment includes an igniterassembly 30 coupled to the firebox 16 and configured to ignite the woodor other fuel within the firebox 16 so as to start a fire in thefireplace unit or to keep the fire going within the firebox 16,especially just after a fire is started and while the firebox 16 is notyet fully warmed up. The igniter assembly 30 includes a mountingassembly 32 attached to the wall of the firebox 16. In the illustratedembodiment, the mounting assembly 32 is mounted on the back wall 18 ofthe firebox 16, although the mounting assembly 32 can be mounted toother portions of the firebox 16 or to the fireplace housing 14 in otherembodiments. The mounting assembly 32 is connected to and supports anigniter 34 in a selected location and orientation relative to thefirebox 16 and the interior area 26. As best seen in FIGS. 3 and 4, theigniter 34 has an ignition end 36 that extends through an aperture 38 inthe firebox's back wall 18, such that the ignition end 36 is locatedwithin or in direct communication with the interior area 26 in thefirebox 16. The igniter 34 is configured to provide an ignition source,such as superheated air or other air source that generates sufficientheat to ignite the wood/fuel or to facilitate continued burning. In oneembodiment, the aperture 38 through which the ignition and 36 of theigniter 34 extends is sealed so as to prevent exhaust from passingthrough the aperture 38 during operation of the fireplace assembly. Sucha sealed arrangement is used when the fireplace assembly 10 includes adirect vent fireplace assembly.

The igniter 34 is mounted relative to the firebox so as to direct thesuperheated air downwardly toward the fuel area within the firebox 16 tofacilitate initial combustion or continued combustions. The igniter 34in other embodiments can be aimed in other manners as appropriate forthe fireplace assembly. The ignition and 36 of the igniter 34 ispositioned adjacent to the back wall 18 without projecting extensivelyinto the firebox 16, thereby protecting the igniter's ignition end 36from being damaged, for example, when wood or other fuel is added intothe firebox 16 during operation of the fireplace assembly 10.

The igniter 34 of the illustrated embodiment in an electrical igniterthat contains an electrical heating element that, upon activation, glowsred-hot and generates sufficient heat to ignite the wood/fuel. In oneembodiment, the igniter 34 is a Model HAC0030, manufactured by TempcoMfg. A rear portion 40 of the igniter is exterior of the fire box andmounted to the mounting assembly 32. The rear portion 40 of the igniter34 includes electrical connectors 42 that couple the igniter'selectrical element (not shown) to a power source.

The rear portion 40 of the igniter 34 also includes a nipple 44configured to attach to an air line 48, which is connected to an airsupply 36 or other selected air source. In the illustrated embodiment,the air supply 46 is mounted to a support structure 50 attached to theback of the firebox 16. In other embodiments, the air supply 46 and/orthe support structure 50 can be mounted in other locations while beingcoupled to the igniter 34 as described above.

The air supply 46 is configured to blow air through the air line 48,through the nipple 44, and through the igniter so the air flows over theheating element upon activation of the igniter assembly 30. The flow ofair passing over the igniter's heating element is directed out of theigniter's ignition end 36, thereby driving superheated air into thefirebox 16 and against the wood or other fuel therein.

The igniter 34 and the air supply 46 are operatively connected to acontroller 60, which is configured to control operation of the igniterassembly 34. The controller 60 can be activated so as to control theigniter 34 and the air supply 46 via controls mounted on the fireplaceassembly 10 and/or via a remote control device that wirelesslycommunicates with the controller 60. The controller 60 of theillustrated embodiment can be a Viking Model RC2A Remote Touch ToneRelay Controller manufactured by Viking Electronics of Hudson, WI. Otherembodiments can use other controllers.

The controller 60 can be configured to provide a plurality of operationmodes of the igniter assembly 30. For example, the controller 60 in oneembodiment is configured with a “start mode” for use when initiallystarting a fire in the firebox. In the start mode, the controller 60activates the igniter 34 and the air supply 46 so as to provide asubstantially continuous flow of superheated air into the firebox thatblows against the wood/fuel therein until the wood/fuel is heated to itsignition temperature, thereby starting the wood/fuel to burn. The airsupply 46 and the igniter 34 remain on for a selected period of time toensure that the fire is started in the firebox 16.

In one embodiment, the “start mode” can end after the fire has startedor after a selected time period has elapsed. In another embodiment, the“start mode” can include a post-start, “sustain mode” wherein the airsupply 46 and igniter 34 are cycled off and on for selected time periodsafter the fire is initially started to cyclically provide thesuperheated air to the fuel that will support continued burning of thefuel in the firebox 16. In another embodiment, the “sustain mode” can bea distinct mode separate from the “start mode” that a user can selectwhen activating the ignition system 30. The controller 60 can alsoinclude other modes, such as a “new fuel mode,” wherein the igniter 34and air supply 46 may be activated continuously or cyclically for one ormore selected periods of time when or just after new fuels has beenadded into the firebox 16. The controller 60 can also be configured toindependently activate the air supply 46 when the igniter 34 is turnedoff, thereby directing a flow of non-heated focused combustion air tothe burning fuel. Accordingly, the air supply 46 can be used as afocused air flow to “fan the fire.”

In one embodiment, the igniter assembly 30 can include or be connectedto one or more temperature sensors 62 coupled to the controller 60 thatmonitor the temperature within the firebox 16. The controller 60 canactivate or deactivate the igniter 34 based upon the temperature withinthe firebox 16 as sensed by the temperature sensor(s). For example, ifthe temperature within the firebox 16 is below a threshold level, thecontroller 60 can activate the igniter 34 and air supply 46 so as toinitiate and/or sustain combustion of the fuel in a firebox 16 until thetemperature in the firebox has exceeded the threshold level. After thesensors 62 indicate that temperature has exceeded the threshold level,the controller 60 can deactivate or turn off the igniter 34 and/or theair supply 46. In one embodiment, if the temperature sensors indicatethat the temperature within the firebox 16 drops below load a thresholdlevel, the controller 60 can reactivate the igniter assembly 30 so asrestart or keep the fire burning in the firebox 16. The controller 60can also be configured to turn off the igniter assembly 30 if, as anexample, a selected amount of time has elapsed and if the temperature inthe firebox 16 has not exceeded the threshold level, which may indicatethat there is no longer enough wood or other fuel in the firebox tosustain a fire.

The illustrated embodiment shows a single igniter assembly 30 mounted tothe back of the firebox 16. Other embodiments can include a plurality ofigniter assemblies coupled to one or more controllers 60. Each igniterassembly 30 can be connected to a dedicated air supply. In otherembodiments, multiple igniters 34 can be coupled to a single air supply.

The controller of the igniter 34 is mounted to the back wall andoriented so as to direct the superheated air downwardly toward the fuelarea within the firebox 16 the igniter 34 in other embodiments can beaimed in other manners as appropriate for the fireplace assembly. Theignition and 36 of the igniter 34 is positioned adjacent to the backwall 18 without projecting extensively into the firebox 16, therebyprotecting the igniter's ignition end 36 from being damaged for examplewhen wood or other fuel is added into the firebox 16 during operation ofthe fireplace assembly 10.

FIGS. 5-8 are views of a wood-burning fireplace assembly 10 with anautomatic igniter system 12 in accordance with an alternate embodiment.In this alternate embodiment, the automatic igniter system 12 includesthe mounting assembly 32 and the igniter 34 mounted to a side panel 72of the fireplace housing 14. The side panel 72 can be a separate panelspaced apart from one of the side walls 20 of the firebox 16. The sidepanel 72 has an aperture 74 and the adjacent sidewall 20 has a coaxialthe aligned aperture 76 through which the igniter 34 extends. In thisembodiment, the ignition end 36 of the igniter 34 is positioned adjacentto the sidewall 20 of the firebox 16, and the igniter 34 is aimed at soas to direct the flow of air on to the wood or other fuel in the firebox16 as discussed above. The aperture 76 in the sidewall 20 of the firebox16 can be sealed to maintain a substantially sealed firebox duringoperation of the fireplace assembly 10.

In this alternate embodiment, the igniter 34 is connected to an airsupply 46 and a controller 60 in a manner similar as discussed above,and the controller 60 is configured with one or more of the operationalmodes that a user can select to start or maintain a fire in the firebox.In the illustrated embodiment, a single igniter assembly 30 is providedon one side of the fireplace assembly 10. In another embodiment, anigniter assembly 30 can be provided on each side of the fireplaceassembly 10. In yet another embodiment.

In operation, when a user wants to start a fire in the fireplaceassembly 10, the user opens the door 24, places wood, kindling, paper,or other fuel in the firebox 16 in alignment with the ignition end 36 ofthe igniter, thereby preparing or “setting” the fire. While the user issetting the fire, the igniter assembly remains in an “off” condition.The door 24 or the firebox 16 may be configured with one or more sensorsconnected to the controller 60 to determine if the door is open or fullyclosed. The controller 60 can be configured to activate the igniter 34only is the door 24 is fully closed. The igniter 34 will beautomatically turned off when the door 24 is opened.

After the user has set the fire and fully closes the door 24, the useractivates the controls on the fireplace assembly 10 or on a remotecontroller, so as to select an operation mode of the igniter assembly30. For example, the user can select the “start” mode, wherein thecontroller 60 actives the air supply 46 and the igniter 34 to directheated air into the set fuel until the temperature of the fuel increasesto or past the ignition or flash point, thereby causing the fuel tocatch fire. The user can also select an operation mode wherein theigniter assembly 30 is automatically intermittently turned on and off soas to ensure that the fuel continues to burn. In another embodiment, theuser can manually light the fire in the firebox 16 before closing thedoor 24, and after the door 24 is closed, the igniter assembly 30 can beactivated in a “sustain” mode to direct the superheated air to the fuelto keep the fire burning. After the fire is going continuously and/orwhen the temperature in the firebox 16 has exceeded a threshold level,or after a predetermined time period has elapsed, the controller 60 canautomatically turn off the igniter assembly 30.

From the foregoing, it will be appreciated that specific embodiments ofthe invention have been described herein for purposes of illustration,but that various modifications may be made without deviating from theinvention. Additionally, aspects of the invention described in thecontext of particular embodiments or examples may be combined oreliminated in other embodiments. Although advantages associated withcertain embodiments of the invention have been described in the contextof those embodiments, other embodiments may also exhibit suchadvantages. Additionally, not all embodiments need necessarily exhibitsuch advantages to fall within the scope of the invention. Accordingly,the invention is not limited except as by the appended claims.

I/we claim:
 1. A fireplace assembly for providing fire burning solidcombustible fuel material, comprising: a firebox having walls thatdefine an interior area; an igniter assembly coupled to the firebox andcontaining a heating element, the igniter assembly having an ignitionend extending through an aperture in one wall and being positioned indirect communication with the interior area, wherein the fuel materialcan be immediately adjacent to the ignition end, the igniter assemblyhaving a rear portion exterior of the fire box, the rear portion havinga first connector coupled to the heating element and coupleable to powersource, and having a second connector coupleable to an air source andpositioned to provide air flow over the heating element and out of theignition end and into the firebox for impingement with the combustiblefuel; a temperature sensor connected to the igniter assembly andconfigured to monitor the temperature within the firebox; and acontroller operatively coupled to the igniter assembly and thetemperature sensor, the controller controlling operation of the heatingelement, the temperature sensor, and the air flow through the igniterassembly, wherein the controller can activate and deactivate the igniterassembly based upon the temperature within the firebox as sensed by thetemperature sensor.
 2. A wood-burning fireplace assembly, comprising: afireplace housing containing a firebox defined by a plurality of wallssealably interconnected to define an interior area configured to containsolid combustible fuel material for burning in the firebox; An igniterassembly is coupled to the firebox and configured to ignite the solidcombustible fuel within the interior area so as to start a fire in theinterior area or to keep the fire going within the firebox, the igniterassembly includes a mounting assembly attached to one of the pluralityof walls of the firebox, and an igniter is connected to and supported bythe mounting assembly in a selected location and orientation relative tothe interior area, the igniter having an ignition end that extendsthrough an aperture in the one wall, such that the ignition end islocated in direct communication with the interior area, a rear portionof the igniter is exterior of the fire box and mounted to the mountingassembly, the rear portion of the igniter has electrical connectorsconfigured to couple the igniter to a power source, and the rear portionof the igniter has a nipple configured to attach to an air line coupledto an air source, and the air line is mounted to a support structureattached to the one wall of the firebox 16, wherein the air supply isconfigured to blow air through the air line, through the nipple, andthrough the igniter so the air flows over the heating element uponactivation of the igniter assembly, wherein the air flow passing overthe heating element is directed out of the igniter's ignition end,thereby driving superheated air into the firebox and against the solidcombustible fuel; A controller operatively coupled to the igniter andthe air supply, the controller being configured to control operation ofthe igniter assembly, the controller having a plurality of operationmodes of the igniter assembly, and A temperature sensor connected to theigniter assembly and coupled to the controller and configured to monitorthe temperature within the firebox, wherein the controller can activateor deactivate the igniter based upon the temperature within the fireboxas sensed by the temperature sensor.